aes pharma wall & walkable ceiling cleanroom …...aes pharma wall & walkable ceiling...

AES Pharma Wall & Walkable Ceiling Cleanroom System

Walls

A r c h i t e c t u r a l D e t a i l s

SECTION ONE

AES 2” PVC Pharma Wall System

AES Half-Inch Lining System Detail Return Air via Raised Airwall

Return Air via Full-Height Return PVC Coving & Trim UL Listing Raceway

Section One

AES Pharma Wall Systems

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AES Pharma Wall & Walkable Ceiling

Architectural Components

Copyright 2012, AES Clean Technology, Inc. Revised 3/23/16.All Rights Reserved. The information in this document is subject to change without notice. AES assumes no responsibility for any errors that may inadvertently appear in this document.

AES PHARMA SYSTEM

AES Pharma Wall Panels

IntroductionThe AES Pharma Wall is a cGMP compliant, FM Global Approved, ICC-ES Certified modular panel architectural system. Pre-engineered panels are resistant to moisture, humidity, microbial or fungal growth, and able to with-stand the harshest of sanitizing and cleaning agents.

Material - Composite PanelAES Pharma Wall consists of a non-combustible aluminum framed composite panel featuring a uPVC finish over gal-vanized sheet steel with a honeycomb core.

CoreAluminum honeycomb core - standardAdditional core options, such as EPS (expanded polystyrene) and XPS (extruded polystyrene), are available to suit the requirements of individual projects.

Panel Facing24 gauge (0.7 mm) thick cold rolled galvanized steel (Zinc coating of 272 g/m2 to both surfaces).

Surface Finish (both sides)Proprietary blend of 4 mil (120µm) thick unplasticized polyvinyl-chloride (uPVC).

Composite Thickness2” (50mm) thick composite panel

1/2” (50mm) thick modified composite panel

UL-Rated Raceways2” x 3” (50mm x 75mm) aluminum framing provides UL listed vertical raceways for use in the installation of electri-cal devices and wiring in the walls.

Framing & ExtrusionsAES Pharma Wall panels are framed with an aluminum extruded section. The extrusion incorporates a groove that accepts an interconnecting tongue to form a rigid panel-to-panel construction.

Mounted on an adjustable, extruded aluminum floor track, the AES Pharma Wall panels have a recessed detail that allows for various flooring materials to be coved and finished flush with the face of the wall panel.

FM Global Approved Lowest flame-spread and smoke-developed test ratings in the industry (15 and 30 respectively), which categorizes the system as a Class A building product according to ASTM E84-91a test # 112536-1

FDA ComplianceAES Pharma Wall Panels conform to FDA standards governing raw materials coming into contact with pharmaceuticals.

System Features• PVC cold-welded seams - No Caulk• PVC floor/ceiling coves - No exposed metal• UL-rated raceway for electrical service• Non-combustible, non-outgassing• Impact resistant• Pre-engineered for predictable, repeatable quality


Architectural Components AES PHARMA SYSTEM


Quality AssuranceAES employs on-going quality control programs for the design, manufacture and installation of the AES Pharma System™

Manufacturing - Made in the U.S.A.The AES Pharma System™ is manufactured under controlled factory conditions in accordance with AES’ Quality Protocol.

A comprehensive full-scope manufacturing quality pro-gram tracks receipt of raw materials through manufactur-ing, crating and shipping of finished product. Finished panels are individually inspected, numbered, and labeled prior to crating.

Polyethylene film applied to the face of each AES wall panel prior to crating remains as a protective cover until installation is complete. Film is removed in the field just prior to PVC cold welding of the panel-to-panel joints.

InstallationThe AES Pharma Wall System is implemented as an in-stalled system from AES. Installation is performed by skilled AES technicians, governed by AES Clean-Build Protocol and AES’ project execution best practices.

AES’ Construction Quality Plan (CQP) is created for each project. This plan which is executed and monitored in the field, ensures that quality is maintained as work is being performed; not merely checked at the conclusion of the project during commissioning processes.

The CQP describes the overall strategy, the required speci-fications, and defines the documentation provided. This audited documentation is included as part of the turnover package provided by AES at completion of the project to support the owner’s validation activities.

Installation Essentials• Inspection of all materials, components and equipment upon receipt of goods

• Audit and track all materials from fabrication through installation to ensure compliance with project specifications

• In-process inspections, close-out inspections, formal turnover walk-downs



AES Pharma Raised Airwall for Return Air

IntroductionThe AES Raised Airwall is a curtain wall that provides a continuous opening at the base of the wall system for the purpose of managing return airflow within the facility.

This system provides a fully cleanable detail and allows access into the air chase for inspection purposes.

DetailsAES Raised Airwalls feature double wall construction using AES 2” Pharma Wall panels.

The Raised Airwall panel is supported with a powder coated aluminum base rail, fixed to the full height wall behind it, using stainless steel brackets at nominal 4’ centers.

The Raised Airwall terminates at the underside of the AES Pharma ceiling panel. Openings are formed in the ceiling panels for ductwork connection at the top of the Airwall.

The Raised Airwall allows for the depth as well as the height above the finished floor to be varied to maintain the desired return air velocity.

By eliminating the need for return air grilles, the AES Pharma Raised Airwall provides a cleaner detail and re-duces the number of crevices in the clean space.

An optional stainless steel screen can be provided for inside the cavity of the Raised Airwall to prevent air- borne materials from being introduced in the return air plenum.

Benefits• Creates clean air chase - eliminates need for ductwork below the ceiling level

• Reduces crevices within the cleanroom• Provides a fully cleanable detail


AES PHARMA SYSTEM




AES PHARMA SYSTEM

AES Full-Height Airwall for Return Air

IntroductionAES Full-Height Airwall panel is used to create a box-out detail that forms the clean plenum, complete with return grille, to allow air to return to the HVAC system.

Details

The AES Full-Height Airwall is constructed using the AES 2” Pharma Wall panel with uPVC smooth finish on both sides.

AES Full-Height Airwall allows the cleanroom floor system to be coved flush against the low wall return plenum.

The Full-Height Airwall terminates at the underside of the AES Pharma Ceiling panel. Openings are formed in the ceiling panels for ductwork connection at the top of the Airwall.

The depth of the Full-Height Airwall can be varied to main-tain the desired return air velocity.

Stick-built vs. Modular Comparisonfor Return Air Detail

AES Pharma System™ Stick-Built

Pre-engineered, AES Pharma Wall panels are used to form clean return air cavities.

Cavity wall built with drywall construction method Add material cost for sheet metal return air drops inside of drywall construction.Add labor cost for sheet metal contractorAdd to schedule for sheet metal contractor.Add time in schedule for inspection.



AES PVC Radius Coving & Trim

IntroductionAES’ 3” PVC radius cove, an exclusive design principle, provides an aseptic detail at all wall-to-wall and wall-to-ceiling junction, to create a homogenous cleanroom system.

Description• 3” (75 mm) radius cove• White, extruded PVC to match wall surface• Vacuum-formed corner pieces• uPCV coated metal trim made of the same wall material and formed to provide a variety of folded profiles for external corners, and conditions, and equipment interferences.

PVC WeldsAll wall-to-wall panel joints, ceiling-to-ceiling panel joints, coves, and trims, are sealed with a white liquid uPVC system that forms a weld between the adjacent panel surfaces and creates a homogeneous finish throughout the cleanroom.

All other room features, including door frames, trims, fixtures, and fittings will be sealed with a white, liquid uPVC filler.

Alternative sealants will be used when materials are incompatible with the liquid uPVC system, such as glazing and flooring materials.

InstallationThe AES PVC Radius Cove is installed at all junctions where the AES Pharma Wall and AES Pharma Ceiling panels join together, and where AES Pharma Wall panels join to form corners. A continuous extruded aluminum section retains the cove in position.

The AES trim pieces are typically installed using hidden fasteners and/or adhesive tape.

Benefits• No exposed metal• Easy-to-clean, total swept detail• Creates a homogenous cleanroom system


AES PHARMA SYSTEM



UL Listed Raceway

IntroductionThe AES Pharma Wall’s exclusive design includes UL listed vertical raceways at the edges of each panel to allow for installation of electrical devices or wiring within the walls.

Dimensions2” x 3” (50 mm x 75mm

CertificationUnderwriters Laboratories, (UL) has granted AssemblyApproval for electrical raceways incorporated into the AES Pharma architectural system, [Prefabricated Buildings] Composite Panels, File Number MH26569. This assembly is under on-going UL follow-up inspections, with the most recent Inspection Report available for review to qualified AES customers.

VoltageReceptacle: 120/250

Light: 120/277

ConstructionTwo electrical raceways are formed on 4’ centers using the AES Pharma Wall panel.

The raceway is a standard component of the AES Pharma Wall, forming the side frames of each panel. The aluminum extrusion forms an integral conduit for electrical wires to be fed vertically through the wall panel from above the cleanroom.

Benefits

• Reduces installation costs

• Speeds placement of wires & cables

• Eliminates surface mounted wires, conduits, etc


AES PHARMA SYSTEM

AES Pharma Wall & Walkable Ceiling Cleanroom System

A r c h i t e c t u r a l D e t a i l s

SECTION TWO

AES Pharma Walkable Ceiling




AES PHARMA SYSTEM

AES Pharma Walkable Ceiling System

IntroductionThe AES Pharma Walkable Ceiling is a cGMP compliant, FM Global Approved modular panel architectural system. Pre-engineered panels are resistant to moisture, humid-ity, microbial or fungal growth, and able to withstand the harshest of sanitizing and cleaning agents.

Durable ceiling panels provide a walkable platform during construction. After construction, AES Walk-able Ceilings provide safe access above the cleanroom for routine maintenance activities.

Material - Composite PanelAES Pharma Walkable Ceiling consists of a non-combusti-ble aluminum framed composite panel with a uPVC finish over galvanized sheet steel with a honeycomb core.

CoreAluminum honeycomb core - standardAdditional core options, such as EPS (expanded poly-styrene) and XPS (extruded polystyrene), are available to suit the requirements of individual projects.

Panel Facing24 gauge (0.7 mm) thick cold rolled galvanized steel (Zinc coating of 272 g/m2 to both surfaces).

Surface FinishCleanroom Side: Proprietary blend of 4 mil (120µm) thick unplasticized polyvinyl-chloride (uPVC).

Top Side Galvaneal (zinc-iron alloy)

Panel Size and Thickness4’ x 10’ (1200mm x 2990mm) (typical)2” (50mm) thick composite panel for 4’ x 10’ panel

5’ x 10’ (1480mm x 2990mm) (optional)3” (75mm) thick composite panel for 5’ x 10’ panel

Loading

Design Load 20 lbs./sq. ft. total uniform distributed load (typical) (Dead Load + Live Load ) For 2” - 4’x10’ panel Greater than 20 lbs./sq. ft. (optional)*I.E. 3” - 5’x10’ system often specified for 35lbs./sq.ft. combined load and more

Pre-Engineered• Apertures for HEPA filters, light fixtures, control devices, and other penetrations are engineered and cut in the factory, or may be cut in the field as required.

• The AES Pharma Walkable Ceiling is designed to accommodates both roomside replaceable and disposable HEPA filters.

• Top or bottom access cleanroom lights are available for use with the system, including the AES “W.O.L.F.” (Walk-On-Light-Fxture) - an AES exclusive top access, flush cleanroom light.

FM Global Approved Lowest flame-spread and smoke-developed test ratings in the industry (15 and 30 respectively), which categorizes the system as a Class A building product according to ASTM E84-91a test # 112536-1



AES Pharma Walkable Ceiling System

Quality AssuranceAES employs on-going quality control programs for the design, manufacture, and installation of the AES Pharma System™

Manufacturing - Made in the U.S.A.The AES Pharma System™ is manufactured under controlled factory conditions in accordance with AES’ Quality Protocol.

A comprehensive full-scope manufacturing quality program tracks receipt of raw materials through manufacturing, crating, and shipping of finished product. Finished panels are individually inspected, numbered, and labeled prior to crating.

Polyethylene film applied to the face of each AES ceiling panel prior to crating remains as a protective cover until installation is complete. Film is removed in the field just prior to PVC cold welding of the panel-to-panel joints.

InstallationThe AES Pharma Walkable Ceiling System is implemented as an installed system from AES Installation is performed by skilled AES technicians, governed by AES Clean-Build Protocol and AES’ project execution best practices.

The AES Pharma Walkable Ceiling uses architectural grade aluminum alloy ceiling beams supported by drop rods and turnbuckles to allow accurate leveling of the flush ceiling system. Typically spaced on 10’ centers, the beams provide 10’ open bays.

Unique flush beam design eliminates the need to hang and level each panel individually. AES Pharma Walkable Ceiling System saves time and cost, and allows greater flexibility for installation and future expansion.

Quality Built-InA Construction Quality Plan (CQP) is developed for each project. This plan which is executed and monitored in the field ensures that quality is maintained as work progresses, rather than merely during commissioning activities.

Benefits• Designed for live loads• Accelerated construction schedule - allows for concurrent activities above/below ceiling during construction phase

• GMP roomside finish• FM Global approved• Pre-engineered for predictable, repeatable quality• Minimizes ceiling hazards associated with stick-built construction

• Safe, easy after market maintenance and inspection• Integration of seismic bracing, available where required


AES PHARMA SYSTEM

aes pharma wall & walkable ceiling cleanroom …...aes pharma wall & walkable ceiling...

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